wago condition monitoring powerpoint - final · measurement of machine vibration and high frequency...

Condition Monitoring

John Ditter

WAGO Corporation

WAGO Corporation - 2 -

Condition Monitoring

John Ditter – WAGO Corporation

Condition monitoring is the process of monitoring

machinery health or condition, such that a significant

change is indicative of a developing failure. It allows

maintenance to be scheduled, or other actions to be

taken to avoid the consequences of failure, before the

failure occurs. The main goal of condition monitoring is to

improve plant production capacity and make the process

more profitable.

What is Condition Monitoring?

A 1998 study by the Department of Trade and Industry in the UK reported that

companies who implement a Condition Monitoring (CM) program at their plant on

average spend 25% less on maintenance than companies that do not have a CM

program.

Types of Maintenance #

• Reactive maintenance or 'breakdown maintenance' – Unplanned

machine breakdown. Usually expensive because replacement parts

may need to expedited and overtime man-hours are often required.

In some cases, cascading failures occurred.

• Preventive maintenance – Scheduled maintenance in an effort to

avoid equipment breakdown and failures. Can be further broken

down into Periodic and Predictive Maintenance.

• Periodic maintenance – Time-based maintenance requiring periodic

checks that include inspecting, servicing and cleaning of the

equipment. Replacing gaskets, lubricating friction points and

inspecting for wear are common activities.

• Predictive maintenance – Utilizing data about the equipment and its

operation to anticipate wear conditions. Through analysis of use

trends and information about the expected useful life of components,

maintenance is scheduled and performed in a manner that maximizes

the parts’ useful service life.

Why Condition Monitoring#

• Reduction of Breakdowns

• Anticipate and Plan Repairs

• Increase Profits

• Maintain Plant Production Capacity

• Provide Reasonable work Hours for Maintenance People

Metrics of Condition Monitoring

Vibration

Current

Temperature

How do I monitor these Metrics?

Portable devices???

Portable test equipment can be used for gaining information for trouble shooting and short term collection of needed data. For Predicative maintenance long term data collection and analytics is needed.

Continuous Online Monitoring is a Better Approach!!

Vibration Module & Accelerometer

Power Measurement Modules and Accessories

RTDs, Thermocouples, and Thermistor Modules

24/7 Monitoring

Failures can be Fast or Slow

Failure

Warning

Quick Failure (e.g. Inner Ring – roller bearing damge , wave cracks)

Slow Failure (e.g. Outer Ring – roller bearing damge , tooth flank wear)

WAGO-I/O-SYSTEM 750 – Fieldbus-Independent IO and PLC

Versatile and flexible

• PLCs and/or Remote IO

• Fieldbus-Independent

• Compact (16 channels in 12 mm (0.47in)

• Integrate into existing systems or standalone

• Mounts directly on DIN rail

• More than 500 function modules

• Modular design, easy handling

• Scalable control solutions

• Up to 250 modules/node

Remote IO Example – Extention of Existing PLC System

V • Continuous Monitoring (24/7)

• Monitor Shock, Vibration, Current, and

Temperature in one system

• Per-made function blocks for Siemens and

Rockwell

Visualization

& Historian

Siemens, AB, G

Sensors

PROFINET, PROFIBUS, EtherNet/IP,G

Function Blocks for 3rd Party Software

RSLogix5000 Add-on Instructions

Step 7 Function Blocks

Example - Standalone System

V • WAGO PLC with CoDeSys Program

• Continuous Monitoring (24/7)

• Monitor Shock, Vibration, Current, and

Temperature in one system

• Send alerts via Email and Text-Message

• Send Condition data directly to SQL via PLC

Visualization

& Historian

Sensors

Email Alerts,

Cloud Storage,

The WAGO 750-645 module is used for online monitoring of machine vibration.

The module collects the two most important parameters for machine condition

analysis: Vibration Velocity and Shock Pulse.

750-645 Vibration Monitoring Module

2-Channel Module

2 Threshold limits can be configured:

Warning, & Alarm

2 Digital Outputs for diagnostics

RMS and SPM can be read as process data

from the module

Module is configured via WAGO-IO-CHECK

or WAGO-IO-PRO program

WAGO-IO-CHECK includes ISO 10816-3

Guidelines for vibration

750-645 Technical Data

The WAGO 750-645 uses of a special Tandem-Piezo® sensor allows

measurement of machine vibration and high frequency shock pulses at the

same time.

It is suitable for vibration measurements up to 10 KHz, shock pulse

measurement on rolling bearings, as well as pump cavitation measurement.

750-925 Tandem-Piezo® Acceleration Sensor

Vibration Velocity and Shock Causes

Vibration

Velocity

Lower Frequency Oscillations and Strong Spikes – measured in mm/s RMS

Higher Frequency Oscillations with Impact Pulses and Acceleration

Misalignment

Unbalanced

VibrationMotor

Failure

Turbulence

Aerodynamics Foundation

Failure

Bearing

Failure

IssuesBad or No

ISO 10816-3

RMS vibration velocity

Vibration based condition monitoring

The following illustration shows the criteria for an analysis of the vibration

severity values. The classification depends on the capacity and installation of the

machine.

A: newly

commissioned

B: unlimited long-term

operation admissible

C: short-term

operation admissible

D: vibration causes

damage

Rigid installation Flexible installation

Rigid versus Flexible Foundation

Shock Pulse Measurement – Roller Bearings

There are two shock waves that are continously monitored:

Carpet - Is the general operating noise of the bearings and machine –

baseline noise

Peak - Is the sharp amplitude spike as age and wear become a factor.

As the machine wears and ages, the carpet value will start to rise.

As shock pulses increase the information can diagnose the state of the machine.

Maintanance can schedule a shutdown to fix the performance of the machine

before it costs big money and production losses.

Low Carpet + Low Peak

= Good Condition

High Carpet + Low Peak

= Needs Grease

The carpet value rises when the lubrication layer decreases and rolling path

and roller bearings touch at more and more locations. The diagram below

shows an increased carpet value

low carpet + high peak

= damaged bearing or polluted

grease

rising carpet + rising peak

= limited operation possible, bearing will

be damaged soon

If the sensor is mounted on

the bolted section or

welded area the sound

waves will not provide the

best of conditions for

optimum sensor

performance.

The Tandem-Piezo

Sensor must be

mounted on the

solid bearing block.

This transfers the

best shock waves to

the sensor

Sensor Mounting

Loaded region

Shock pulses are generated mainly in the rolling interface, where the load

carrying element touches the raceway. Therefore, the measurement must be

located in the loaded region of the bearing housing (as defined by the

bearing's emission window see below). Ideally, the measurement point

should be in line with the load direction.

Sensor Mounting Rules

One mechanical interface

Each interruption (or interface) in the material dampens the signal to be

measured. Therefore, the signal path must contain only one mechanical

interface, that between the bearing and the bearing housing.

The amount of signal loss at

an interface can be

considerable.

Welds, for example, are

regarded as interfaces.

Short signal path

The signal path between the bearing and the measurement point must be as

short and straight as possible.

Shock pulses lose

strength over a long

signal path

(especially when it

has a large cross

section) and are

dampened when

deflected by bends in

the path. Note that

measurement is

possible only in the

area defined by the

dotted lines.

WAGO-I/O-Check Configuration

Group 1: 400HP - 67051HP

Group 2: 20HP – 400HP

Group 3: Pumps External Drive

Group 4: Pumps Internal Drive

Rigid / Flexible Foundation

Wago-I/O-Check ISO Settings

Vibration & Shock Demo

3-Phase Power Measurement Modules

Power Measurement Modules

Monitoring Current can help diagnoseG

• Phase lose

• Imbalanced Phases

• Overloaded Systems/Motors

• Blinding of mechanical parts

• Lubrication Issues

• Failing Motors

750-493 750-494 750-495

Voltage measurement 3~ 480 V 3~ 480 V 3~ 480 V / 690 V

Current measurement 1 A (750-493)

5 A (750-493/000-001)

1 A (750-494)

5 A (750-494/000-001)

1 A (750-495)

5 A (750-495/000-001)

Active energy/power/factor � � �

Phase position � � �

Reactive power/energy via function block � �

Apparent power/energy via function block � �

Rotary field detection � �

Power factor (�) � �

Frequency measurement � � �

Four-quadrant operation (inductive,

capacitive, load, generator)

� �

Harmonic analysis (up to 41th harmonic) � �

Tamper detect (Neutral measure) �

Solid Core Current Transformer

Rogowski Coil

Split Core Current Transformer

WAGO-I/O-CHECK

Visualization of

measured values

Adjust parameters

Calibration of

3-Phase Power

Measurement Modules

WAGO-I/O-CHECK

Visualization of

measured values

3 Phase Power Monitoring

Current Signal Conditioners

Jump Flex CT and Rogowski Signal Conditioners

Temperature Measuring Devices

Thermocouple ModulesType: J, K, B, E, N, R, S, T, U and L

RTD ModulesPt 100,Pt 200, Pt500, Pt 1000,

Ni 100, Ni 120, Ni 1000

TK6180,TK5000,

KTY81 110, KTY81 210

NTC 20k

PTC Module

JumpFlex RTD and Thermocouple Modules

Summary

Condition Monitoring#

• is fast and easy to implement in new or existing machines.

• reduces unexpected downtimes.

• lowers overall maintenance costs and increases bottom

line profits.

• helps provide a reasonable work schedule for

maintenance personnel.

Thank you!

wago condition monitoring powerpoint - final · measurement of machine vibration and high frequency...

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